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2008 RZR
Polaris 2008 RZR User Manual
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7.35
FINAL DRIVE
7
WHEEL HUBS
Front Hub Exploded V
iew
Rear Hub Exploded View
Flanged Nut
s
Front Rim
Va
l
v
e
Castle Nut
Cotter Pin
Cone
Wheel Hub
St
u
d
Brake Disc
Bolts
Retaining
Sealed
Ball Bearing
Bearing Carrier
Front T
ire
W
ashers
See Page 7.2
for T
orque V
alue
80 ft. lbs.
(108 Nm)
Ring
Flanged Nut
s
Front Rim
Va
l
v
e
Castle Nut
Cotter Pin
Cone
Wheel Hub
St
u
d
Brake Disc
Bolts
Retaining
Sealed
Ball Bearing
Bearing Carrier
Front T
ire
W
ashers
See Page 7.2
for T
orque V
alue
80 ft. lbs.
(108 Nm)
Ring
228
230
Table of Contents
General Information Chapter
1
Table of Contents
1
Chapter 1
2
Engine Designation Number
2
Engine Serial Number Location
2
General Information
2
Model Identification
2
Model Information
2
Vin Identification
2
Unit Serial Number (Vin) Location
3
General Specifications
4
Model: 2008 Ranger Razr
4
Special Tools
6
Vehicle Information
6
Publication Numbers
6
Paint Codes
6
Replacement Keys
6
Misc. Specifications and Charts
7
Conversion Table
7
Standard Torque Specifications
8
Sae Tap / Drill Sizes
9
Metric Tap / Drill Sizes
9
Glossary of Terms
10
Maintenance Chapter 2 Maintenance 2
11
Break-In Period
13
Chapter 2
13
Maintenance Chart Key
13
Periodic Maintenance Chart
13
Periodic Maintenance Overview
13
Pre-Ride - 25 Hour Maintenance Interval
14
50 - 300 Hour Maintenance Interval
15
Component Inspection / Service Locations
16
Front and Rear View
16
Rh and Lh Side Views
17
Lubricants / Service Products
18
Polaris Lubricants, Maintenance and Service Products
18
Maintenance References
19
General Vehicle Inspection and Maintenance
20
Pre-Ride / Daily Inspection
20
Frame, Nuts, Bolts, and Fasteners
20
Shift Cable Inspection / Adjustment
20
Fuel System and Air Intake
21
Fuel System
21
Fuel Line
21
Fuel Pump / Fuel Filters
21
Vent Lines
21
Throttle Pedal Inspection
22
Throttle Freeplay Adjustment
22
Air Filter Service
22
Engine
24
Engine Oil Level
24
Engine Oil and Filter Service
25
Engine Breather Hose Inspection
26
Engine and Transmission Mount Locations
26
Compression and Leakdown Test
26
Exhaust - Spark Arrestor
26
Transmission and Gearcases
27
Transmission / Gearcase Specification Chart
27
Transmission Lubrication
27
Front Gearcase Lubrication
29
Rear Gearcase Lubrication
30
Cooling System
31
Cooling System Overview
31
Coolant Level Inspection
31
Coolant Strength / Type
31
Cooling System Pressure Test
32
Cooling System Hoses
32
Radiator
32
Coolant Drain / Radiator Removal
32
Final Drive / Wheel and Tire
33
Wheel, Hub, and Spindle Torque Table
33
Wheel Removal
33
Wheel Installation
33
Tire Inspection
34
Tire Pressure
34
Drive Shaft Boot Inspection
34
Electrical and Ignition System
35
Battery Maintenance
35
Battery Removal
35
Battery Installation
35
Battery off Season Storage
36
Battery Charging (Sealed Battery)
36
Spark Plug Service
36
Engine to Frame Ground
37
Steering and Suspension
37
Steering
37
Steering Wheel Inspection
37
Steering Inspection / Tie Rod Ends and Hubs
38
Toe Alignment Inspection
38
Toe Adjustment
39
Suspension Spring Preload Adjustment
39
Brake System
40
Brake Fluid Inspection
40
Brake Pad / Disc Inspection
40
Brake Hose and Fitting Inspection
40
Engine
41
Chapter 3
42
Crankcase Exploded Views
42
Engine Specifications
42
Engine Fastener Torque Patterns
47
Torque Specifications
48
800 EFI Engine Service Specifications
49
Special Tools
51
Engine Cooling System
52
Cooling System Specifications / Pressure Test
52
Cooling System Exploded View
53
Cooling System Bleeding Procedure
54
General Engine Service
55
Engine Lubrication Specifications
55
Accessible Engine Components
55
Oil Pressure Test
55
Oil Flow Chart
56
Engine Removal
57
Engine / Transmission Separation
63
Engine Disassembly and Inspection
64
Cylinder Head Assembly Exploded View
64
Rocker Arms / Push Rods
65
Cylinder Head Removal
65
Cylinder Head Inspection / Warp
66
Valve Seal / Spring Service (on Engine)
66
Cylinder Head Disassembly
67
Valve Inspection
68
Combustion Chamber
69
Valve Seat Reconditioning
69
Cylinder Head Reassembly
71
Valve Sealing Test
72
Cylinder Removal
72
Valve Lifter Removal / Inspection
72
Piston Removal
73
Cylinder Inspection
74
Cylinder Hone Selection and Honing Procedure
75
Honing to Deglaze / Cleaning the Cylinder after Honing
75
Piston-To-Cylinder Clearance
76
Piston / Rod Inspection
76
Piston Ring Installed Gap
77
Starter Drive Bendix Removal / Inspection
77
Flywheel / Stator Removal / Inspection
78
Engine Crankcase Disassembly / Inspection
78
Camshaft Inspection
86
Engine Reassembly
87
Crankcase Reassembly
87
Flywheel / Stator Installation
96
Cylinder Head Reassembly
96
Oil Pump Priming
98
Engine Installation
99
Engine Assembly and Installation
99
Engine Break-In Period
101
Troubleshooting
102
Engine
102
Cooling System
103
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection
105
Chapter 4
106
Electronic Fuel Injection
106
General Information
106
Special Tools
106
Service Notes
109
Efi System Exploded View
110
Efi System Component Locations
111
Fuel Tank
113
Exploded View
113
Fuel Lines - Quick Connect
114
Electronic Fuel Injection
114
Principal Components / Efi Operation Overview
114
Initial Priming / Starting Procedure
115
Electronic Control Unit (Ecu)
115
Temperature and Barometric Air Pressure Sensor (T-Bap)
116
Crankshaft Position Sensor (Cps)
117
Cps Test
117
Cps Replacement
118
Fuel Injectors
122
Fuel Injector Service
122
Fuel Pump
125
Fuel Sender Test
125
Fuel Pump Test
125
Fuel Tank / Fuel Pump Replacement
127
Fuel Pressure Regulator
129
Throttle Position Sensor (Tps)
130
Tps Test Procedure
130
Tps Initialization
132
Tps Replacement
133
Engine Coolant Temperature Sensor (Ect)
134
Ignition Coil
135
Diagnostic "Blink Codes
136
Efi Troubleshooting
137
General Troubleshooting
136
Efi System Breakout Diagrams
138
Diagnostic Connector Circuit
138
Malfunction Indicator Lamp (Mil) Circuit
138
Fuel Injector (Pto) Circuit
139
Fuel Injector (Mag) Circuit
139
Engine Coolant Temperature Sensor (Ect) Circuit
140
Engine Overheat Lamp Driver Circuit
140
Crankshaft Position Sensor (Cps) Circuit
141
Air Temperature / Manifold Air Pressure Sensor (T-Bap) Circuit
141
Throttle Position Sensor (Tps) Circuit
142
Fuel Pump Circuit
142
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension
143
Special Tools
144
Torque Specifications
144
Cab Frame
145
Chapter 5 Assembly / Removal
145
Body Exploded Views
146
Dash Instruments / Controls
146
Front Bumper
147
Rear Bumper
147
Hood / Front Body Work
148
Seat Assembly
149
Seat Belts / Mounting
149
Floor / Rocker Panels
150
Rear Cargo Box / Fenders
151
Chassis / Main Frame
152
Body Component Removal
153
Seats
153
Rear Service Panel
153
Front Bumper
153
Rear Bumper
153
Hood and Front Body Work
154
Rocker Panels, Console and Floor
155
Steering Assembly
156
Exploded View
156
Wheel Hubs
157
Front Hub Exploded View
157
Rear Hub Exploded View
157
Front A-Arms
158
Removal / Replacement
158
Exploded View
159
Ball Joint Service
159
Removal
159
Installation
160
Front Stabilizer Bar
161
Sway Bar Linkage Removal
161
Stabilizer Bar Removal
161
Exploded View
162
Rear A-Arms
163
Removal
163
Installation
164
Rear Stabilizer Bar
165
Removal / Installation
165
Decal Replacement
166
Shocks / Springs
166
Exploded View
166
Shock Removal / Installation
166
Shock Replacement
166
Clutching Chapter 6 Clutching
167
Chapter 6 Pvt System Fastener Torques
168
Pvt System Overview
168
General Operation
168
Drive Clutch Operation
168
Driven Clutch Operation
169
Pvt Break-In (Drive Belt / Clutches)
169
Maintenance / Inspection
169
Overheating / Diagnosis
170
Special Tools and Supplies
168
Torque Specifications
168
Pvt System Service
171
Pvt Sealing and Ducting Components
171
Disassembly
171
Assembly
172
Drive Belt
173
Belt Removal
173
Belt Inspection
174
Belt Installation
174
Pvt Break-In (Drive Belt / Clutches)
174
Drive Clutch Service
175
Spring Specifications
175
Shift Weights
176
Exploded View
177
Clutch Disassembly
177
Spider Removal
178
Roller, Pin, and Thrust Washer Inspection
179
Button to Tower Clearance Inspection
179
Shift Weight Inspection
179
Bearing Inspection
180
Clutch Inspection
180
Moveable Sheave Bushing Inspection
181
Bushing Service
182
Clutch Assembly
184
Driven Clutch Service
185
Clutch Disassembly
185
Bushing Service
187
Clutch Assembly
189
Exploded View
192
Troubleshooting
193
Final Drive Chapter 7 Final Drive
195
Chapter 7 Wheel, Hub, and Spindle Torque Table
196
Front Bearing Carrier
196
Bearing Carrier Inspection / Removal
196
Bearing Replacement
197
Bearing Carrier Installation
198
Special Tools
196
Torque Specifications
196
Front Drive Shaft
200
Drive Shaft Removal
200
Drive Shaft / CV Joint Handling Tips
201
CV Joint / Boot Replacement
201
Drive Shaft Installation
202
Propshaft Service
204
Removal / Installation
204
Propshaft U-Joint Service
204
Disassembly
204
Assembly
205
Front Gearcase / Centralized Hilliard
206
Centralized Hilliard Exploded View
206
All Wheel Drive Operation
207
Awd Diagnosis
208
Gearcase Removal
209
Gearcase Disassembly / Inspection
209
Gearcase Assembly / Inspection
211
Backlash Thrust Plate Adjustment
213
Gearcase Installation
214
Rear Bearing Carrier
215
Bearing Carrier Inspection / Removal
215
Bearing Replacement
216
Bearing Carrier Bushing Replacement
216
Bearing Carrier Installation
217
Wheel Hub
217
Rear Drive Shaft
218
Removal
218
CV Joint / Boot Replacement
219
Installation
221
Rear Gearcase
223
Gearcase Removal
223
Gearcase Disassembly
224
Gearcase Assembly
226
Gearcase Installation
227
Gearcase Exploded View
228
Wheel Hubs
229
Front Hub Exploded View
229
Rear Hub Exploded View
229
Transmission Chapter 8 Transmission
231
Chapter 8
232
Installation
232
Removal
232
Shift Lever
232
Torques / Specifications
232
Shift Cable Inspection / Adjustment
233
Transmission Service
234
Transmission Removal
234
Transfer Case Disassembly
234
Transfer Case Reassembly
237
Transmission Shift Housing Disassembly
239
Transmission Shift Housing Reassembly
244
Troubleshooting
249
Troubleshooting Checklist
249
Transmission Exploded Views
250
Shift Housing / Transfer Case Exploded View
250
Brakes Chapter 9 Brakes
251
Chapter 9
252
General Specifications
252
Special Tools
252
Torque Specifications
252
Brake Noise Troubleshooting
253
Brake System Service Notes
253
Brake System Exploded View
254
Hydraulic Brake System Operation
254
Brake Pedal Lever
255
Pedal Removal
255
Pedal Installation
255
Master Cylinder
255
Removal
255
Installation
255
Brake Bleeding / Fluid Change
256
Front Brake Pads
257
Pad Removal
257
Pad Inspection
257
Pad Assembly / Installation
258
Brake Burnishing Procedure
258
Front Caliper Service
259
Caliper Exploded View
259
Caliper Removal
259
Caliper Disassembly
260
Caliper Inspection
261
Caliper Assembly
261
Caliper Installation
262
Front Brake Disc
263
Disc Inspection
263
Disc Replacement
263
Rear Brake Pad
264
Pad Removal
264
Pad Inspection
265
Pad Assembly / Installation
265
Brake Burnishing Procedure
265
Rear Caliper Service
266
Caliper Exploded View
266
Caliper Removal
266
Caliper Disassembly
267
Caliper Inspection
267
Caliper Assembly
268
Caliper Installation
268
Rear Brake Disc
269
Disc Inspection
269
Disc Replacement
269
Troubleshooting
270
Brakes Squeal / Poor Brake Performance
270
Pedal Vibration
270
Caliper Overheats (Brakes Drag)
270
Brakes Lock
270
Electrical Chapter 10 Electrical
271
Chapter 10
273
Electrical Service Notes
273
General Information
273
Special Tools
273
Under-Dash Components
273
Switches / Controls
274
Headlamp Switch
274
Awd Switch
274
Brake Light Switch
274
Instrument Cluster
275
Overview
275
Rider Information Display
275
Standard Display Modes
276
Diagnostic Display Mode
276
Viewing Diagnostic Codes
278
Instrument Cluster Removal
279
Instrument Cluster Installation
279
Instrument Cluster Troubleshooting Tests
280
Test 1 - no All Wheel Drive
280
Test 2 - no Display
281
Test 3 - Vehicle Speed Sensor
281
Test 4 - no Awd Hub Safety Limiter
282
Test 5 - Fuel Gauge Display Not Working
283
Test 6 - Gear Indicator Not Working (Transmission Switch)
283
All Wheel Drive Coil
284
Operation Overview
284
Diagnosing System Failures
284
Gear Position Indicator Switch
284
Test Diagram
284
Speed Sensor
284
Location / Testing
284
Head Lights
285
Headlight Adjustment
285
Headlamp Bulb Replacement
285
Tail / Brake / Work Lights
286
Bulb Replacement
286
Cooling System Schematic
287
Cooling System Break-Out Diagram
287
Fan Control Circuit Operation / Testing
288
Fan Control Circuit Bypass Test
288
Coolant Temperature Sensor
288
Efi Diagnostics
288
Efi Component Testing
288
Fuel Sender
288
Testing
288
Fuse Box Layout
289
Relays
289
Fuses / Circuit Breaker
290
Charging System
291
Current Draw - Key off
291
Charging System "Break Even" Test
291
Charging System Alternator Tests
292
Charging System Testing Flow Chart
293
Battery Service
294
Battery Identification
294
Conventional Battery
294
Battery Activation
294
Battery Inspection
295
Conventional Battery Testing
295
Off Season Storage
297
Charging Procedure (Conventional)
297
Low Maintenance Battery
298
General Battery Information
298
Battery Testing
299
Ocv - Open Circuit Voltage Test
299
Load Test
299
Off-Season Storage
299
Charging Procedure (Low Maintenance)
300
Starting System
300
Troubleshooting
300
Voltage Drop Test
301
Starter Motor Removal / Disassembly
301
Brush Inspection / Replacement
301
Armature Testing
302
Starter Reassembly / Installation
303
Starter Drive
304
Starter Exploded View
305
Starting System Testing Flow Chart
306
Condition: Starter Fails to Turn over the Engine
306
Electrical Breakout Diagrams
307
12V Key-On Power Circuit
307
Starting System Circuit
307
Instrument Cluster Circuit
308
Transmission Switch Circuit
308
Wheel Speed Sensor Circuit
309
Awd Circuit
309
Fuel Gauge Display Circuit
310
Cooling Fan Circuit
310
Charging System Circuit
311
4
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Polaris 2008 RZR Specifications
General
Brand
Polaris
Model
2008 RZR
Category
Utility Vehicle
Language
English
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